U.S. patent number 10,295,186 [Application Number 14/228,574] was granted by the patent office on 2019-05-21 for airblast nozzle with upstream fuel distribution and near-exit swirl.
This patent grant is currently assigned to DELAVAN INC. OF DES MOINES IA. The grantee listed for this patent is Delavan Inc.. Invention is credited to Gregory Zink.
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United States Patent |
10,295,186 |
Zink |
May 21, 2019 |
Airblast nozzle with upstream fuel distribution and near-exit
swirl
Abstract
A nozzle is provided including a nozzle body having an upstream
end and a downstream end aligned about a central axis. A discharge
portion is positioned adjacent the downstream end. A bore extends
inwardly from the downstream end over the length of the discharge
portion. An opening is formed in the nozzle body adjacent the
discharge portion. The opening is fluidly connected to the bore to
provide an interior air flow passage. A main fuel channel extends
from the upstream end to the discharge portion. At least one fuel
flow branch extends through the discharge portion between the bore
and an outer surface of the nozzle body. The fuel flow branch is
fluidly coupled to the main fuel conduit to provide a fuel flow
passage. The outer air cap is positioned about the outer surface of
the discharge portion of the nozzle body to form an exterior air
flow passage.
Inventors: |
Zink; Gregory (Des Moines,
IA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Delavan Inc. |
Des Moines |
IA |
US |
|
|
Assignee: |
DELAVAN INC. OF DES MOINES IA
(Des Moines, IA)
|
Family
ID: |
53178139 |
Appl.
No.: |
14/228,574 |
Filed: |
March 28, 2014 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20160161122 A1 |
Jun 9, 2016 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F23R
3/286 (20130101); F23D 11/106 (20130101); F23D
11/383 (20130101); F23R 3/14 (20130101); F23D
2900/11101 (20130101); F23R 2900/00018 (20130101); F23D
2900/00018 (20130101) |
Current International
Class: |
F23R
3/14 (20060101); F23D 11/10 (20060101); F23R
3/28 (20060101); F23D 11/38 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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|
|
|
|
2451144 |
|
Jan 2009 |
|
GB |
|
2459771 |
|
Nov 2009 |
|
GB |
|
Other References
Office Action for Application No. GB1505181.6 dated Sep. 18, 2015;
7 pages. cited by applicant.
|
Primary Examiner: Kim; Ted
Attorney, Agent or Firm: Cantor Colburn LLP
Claims
The invention claimed is:
1. A nozzle comprising: a nozzle body having an upstream end and a
downstream end aligned along a central axis includes: a discharge
portion being positioned adjacent the downstream end, an inwardly
extending bore is formed at the downstream end and extends along
the central axis over the length of the discharge portion; at least
one airflow opening formed in the nozzle body adjacent the
discharge portion, the at least one opening being fluidly connected
to an interior of the bore to provide an interior air flow passage;
a main fuel conduit extending along the central axis from the
upstream end to the discharge portion; and two or more fuel flow
branches extending through the discharge portion generally between
the bore and an outer surface of the nozzle body, the fuel flow
branches being fluidly coupled to the main fuel conduit to provide
a fuel flow passage through the nozzle body, the fuel flow branches
defining the at least one airflow opening between circumferentially
adjacent fuel flow branches, and axially between the two or more
fuel branches and the discharge portion, wherein the discharge
portion is fluidly coupled to the interior air flow passage; and an
outer air cap positioned about the outer surface of the discharge
portion of the nozzle body such that an outer air flow passage is
formed between an interior of the outer air cap and the nozzle
body; wherein the fuel flow passage, the interior air flow passage,
and the outer air flow passage are configured to intersect near the
downstream end of the nozzle body; wherein the nozzle body further
includes an interior air swirler disposed at the central axis and
arranged within the bore, the interior air swirler including a
plurality of interior air swirler vanes intersecting at the central
axis.
2. The nozzle according to claim 1, wherein the nozzle body is
formed through an additive manufacturing process.
3. The nozzle according to claim 1, wherein the interior air
swirler is integrally formed with the discharge portion of the
nozzle body.
4. The nozzle according to claim 1, wherein the nozzle body further
comprises an outer air swirler surrounding an outer circumference
of the discharge portion.
5. The nozzle according to claim 4, wherein the outer air swirler
includes a plurality of circumferentially disposed vanes.
6. The nozzle according to claim 4, wherein the outer air swirler
is integrally formed with the discharge portion of the nozzle
body.
7. The nozzle according to claim 1, wherein the nozzle body
includes a plurality of airflow openings positioned adjacent the
discharge portion and fluidly coupled to the interior of the
bore.
8. The nozzle according to claim 7, wherein each of the plurality
of airflow openings is substantially equal in size and is
equidistantly spaced about the central axis.
9. The nozzle according to claim 1, wherein each of the two or more
fuel flow branches is substantially identical in size and shape and
is equidistantly spaced about the central axis within the discharge
portion.
10. The nozzle according to claim 1, wherein the nozzle is operably
coupled to a feed arm of a fuel injector, the feed arm having a
fuel conduit and the upstream end of the nozzle body being coupled
to an end of the feed arm such that the fuel conduit of the feed
arm and the main fuel conduit of the nozzle body are fluidly
coupled.
11. The nozzle according to claim 10, wherein the fuel injector is
mounted within a gas turbine engine.
12. The nozzle according to claim 1, wherein at least one heat
shield is integrally formed with the nozzle body.
13. The nozzle according to claim 1, wherein fuel within the two or
more fuel flow branches is provided directly to a plurality of
corresponding fuel exit slots.
Description
BACKGROUND OF THE INVENTION
This invention generally relates to injectors and fuel nozzles for
high temperature applications, and more particularly, to fuel
injectors and nozzles for gas turbine engines.
Gas turbine engines used in military and commercial aircrafts must
satisfy high demands with respect to reliability, weight,
performance, economic efficiency, and durability. Turbine engines
typically include a plurality of fuel injectors configured to
inject fuel in a spray or atomized form into a combustion chamber
of the engine. The atomized air/fuel mixture is then combusted to
create the energy required to sustain engine operations.
The atomization of the fuel/air mixture is generally achieved by
mixing the fuel with a turbulent, non-linear air flow. To create a
turbulent air flow in conventional fuel nozzles, an air swirler is
positioned at an upstream end of the nozzle within the interior air
flow path. As the air flows over the air swirler, the air is forced
to swirl about the circumference of the passage. Because the air
swirler is arranged at the upstream end of the nozzle, the swirl
generated dissipates as the air travels over the length of the
nozzle. By the time the air flow reaches the downstream end where
it is mixed with the fuel, the swirling of the air flow may be
diminished, thereby reducing the atomization of the mixture.
Conventional methods for manufacturing components of a gas turbine
engine include machining, forging, and investment casting. Material
selection for the components that are subjected to high mechanical
loads, high vibration loads, or high thermal loads is often based
upon material limits being exceeded in localized regions of the
component. Because high-strength materials are needed, the cost of
the component is largely driven by the amount of material used, so
elimination of excess weight can significantly reduce part or
component cost.
BRIEF DESCRIPTION OF THE INVENTION
According to one embodiment of the invention, a nozzle is provided
including a nozzle body having an upstream end and a downstream end
aligned about a central axis. A discharge portion is positioned
adjacent the downstream end. A bore extends inwardly from the
downstream end over the length of the discharge portion. An opening
is formed in the nozzle body adjacent the discharge portion. The
opening is fluidly connected to the bore to provide an interior air
flow passage. A main fuel channel extends from the upstream end to
the discharge portion. At least one fuel flow branch extends
through the discharge portion between the bore and an outer surface
of the nozzle body. The fuel flow branch is fluidly coupled to the
main fuel conduit to provide a fuel flow passage. The outer air cap
is positioned about the outer surface of the discharge portion of
the nozzle body to form an exterior air flow passage.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter, which is regarded as the invention, is
particularly pointed out and distinctly claimed in the claims at
the conclusion of the specification. The foregoing and other
features, and advantages of the invention are apparent from the
following detailed description taken in conjunction with the
accompanying drawings in which:
FIG. 1 is a schematic diagram of a gas turbine engine;
FIG. 2 is a cross-sectional view of a fuel injector according to an
embodiment of the invention;
FIG. 3 is a cross-sectional view of a tip of a fuel injector
according to an embodiment of the invention;
FIG. 4 is a perspective cross-sectional view of a tip of a fuel
injector according to an embodiment of the invention;
FIG. 5 is a rear perspective view of a tip of a fuel injector
according to an embodiment of the invention; and
FIG. 6 is a perspective view of a tip of a fuel injector according
to an embodiment of the invention.
The detailed description explains embodiments of the invention,
together with advantages and features, by way of example with
reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic diagram of an embodiment of a gas turbine
engine 10, such as used in an aircraft, for example. The
illustrated gas turbine engine 10 incorporates a fan section 20, a
compressor section 30, a combustion section 40, and a turbine
section 50. The combustion section 40 incorporates a combustor 100
that includes an array of fuel injectors 200 that are positioned
annularly about a centerline 2 of the engine 10 upstream of the
turbine sections 52, 54. Throughout the application, the terms
"forward" or "upstream" are used to refer to directions and
positions located axially closer toward a fuel/air intake side of a
combustion system than directions and positions referenced as "aft"
or "downstream." The fuel injectors 200 are inserted into and
provide fuel to one or more combustion chambers for mixing and/or
ignition. It is to be understood that the combustor 100 and fuel
injector 200 as disclosed herein are not limited in application to
the depicted embodiment of a gas turbine engine 10, but are
applicable to other types of gas turbine engines, and may also be
applicable in industrial applications, such as spray drying for
example.
A fuel injector 200 configured for use in the gas turbine engine 10
is shown in more detail in FIG. 2. The fuel injector 200 includes a
fuel inlet fitting 202 and a fuel injector tip 204 connected to
each other by a feed arm 206. Fuel inlet fitting 202 is provided at
an upstream end 208 of the injector 200 for receiving fuel to be
atomized for combustion and includes a mounting flange 210
configured to attach the injector 200 within a gas turbine engine
10. As illustrated, the fuel inlet fitting 202 may include a check
valve 212 for distributing fuel from the inlet fitting 202 to a
fuel conduit 214 extending through the feed arm 206 to the injector
tip 204. In one embodiment, an insulation gap 216 is provided
between the fuel conduit 214 and the outer wall of the feed arm 206
which may be filled with air, noble gases, a vacuum, or any other
suitable form of insulation to insulate the fuel within the fuel
conduit 214 from the high temperatures outside the feed arm
206.
Referring now to FIGS. 3-6, the fuel injector tip 204 of the fuel
injector 200 is provided in more detail. The injector tip 204
includes a nozzle body 220 having an upstream end 222 arranged
generally within an open end 218 of the feed arm 206, adjacent the
fuel conduit 214. A shoulder 224 of the nozzle body 220 may be
coupled to the end 218 of the feed arm 206, such as with a weld for
example, to limit movement of the nozzle body 220 relative to the
feed arm 206. A discharge portion 228 is located adjacent an
opposite, downstream end 226 of the nozzle body 220. Extending from
the upstream end 222 to the discharge portion 228 along a central
axis A of the nozzle body 220 is a main fuel channel 230. An end
232 of the main fuel channel 230 is fluidly coupled to the fuel
conduit 214 of the feed arm 206 to provide a portion of a flow path
for the fuel through the nozzle body 220.
A bore 240, centered about the central axis A, extends generally
inward from the downstream end 226 of the nozzle body 220 over the
length of the discharge portion 228. As a result, the bore 240 is
fluidly coupled to at least one adjacent opening 238 (discussed
below) to provide an interior air flow path for directing a portion
of the engine compressor discharge air through the discharge
portion 228 of the nozzle body 220. In the illustrated,
non-limiting embodiment, an air swirler 242 is positioned within
the bore 240. The air swirler 242 is configured to increase the
shear of the air as it passes through the outlet 244 at the
downstream end 226 of the nozzle body 220. In one embodiment, the
air swirler 242 is integrally formed with the sidewall 246 defining
the bore 240 in the discharge portion 228 of the nozzle body
220.
One or more fuel flow branches 250 extend from and fluidly couple
to the main fuel channel 230, such as near end 234 for example. As
a result, one or more openings 238 may be formed in the middle
portion 236 of the nozzle body 220 between the adjacent fuel flow
branches 250. In embodiments including a plurality of fuel flow
branches 250, the branches 250 may be substantially similar in size
and shape. In addition, the fuel flow branches 250 may, but need
not be equidistantly spaced circumferentially about the central
axis A within the discharge portion 228 of the nozzle body 220.
Together, the main fuel channel 230 and each of the fuel flow
branches 250 provides a fuel flow passage through the nozzle body
220 to the fuel exit slots 251 (FIG. 6). As a result, the discharge
portion 228 of the nozzle body 220 functions in a manner similar to
a fuel distributor and a swirler of a conventional nozzle. In
addition, one or more heat shields are integrally formed with the
nozzle body 220 adjacent the main fuel channel 230 and each of the
fuel flow branches 250 to protect the fuel therein from the high
temperatures outside the nozzle body 220. Each fuel flow branch 250
includes a first heat shield including a thin air gap disposed
radially outboard of the inner air swirler, and a second heat
shield including a thin air gap formed radially inboard of the
outer air swirler.
The outer air swirler 260, surrounding the circumference of the
outer surface 252 of a part of the discharge portion 228 includes a
plurality of circumferentially disposed vanes 262. In one
embodiment, the outer air swirler 260 is integrally formed with the
outer surface 252 of the discharge portion 228 of the nozzle body
220. Positioned adjacent the downstream end 226 of the nozzle body
220 and surrounding the plurality of vanes 262 of the outer air
swirler 260 is the outer air cap 270, which can also be formed
integrally to the nozzle body 220. Together the outer air swirler
260 and the interior 272 of the adjacent outer air cap 270, define
an exterior air flow passage for directing engine compressor
discharge air toward the downstream end 226 of the nozzle body to
mix with the fuel issuing therefrom.
In operation, fuel flows through each of the plurality of fuel flow
passages defined by the fuel branches 250 within the discharge
portion 228 of the nozzle body 220. As the fuel flows arrives at
the outlet 244 of the downstream end 226 of the nozzle body 220,
the fuel mixes with both the exterior air flow and the interior air
flow. In one embodiment, a portion of each of the fuel flow
branches 250 adjacent the downstream end 226 of the nozzle body is
contoured to direct the fuel flow towards the interior air flow
path.
In one embodiment, the nozzle body 220, including the interior air
swirler 242 and the outer air swirler 260, is formed through an
additive manufacturing process, such as three-dimensional printing,
selective laser sintering (SLS), electron beam melting (EBM), and
direct metal laser sintering (DMLS) for example. In an additive
manufacturing process, a computer model of a component, such as the
nozzle body 220 for example, is divided into a plurality of
cross-sectional layers. Energy is applied to a generally powdered
material, such as cobalt chrome, Inconel, or another high
temperature metal for example, to create each of the plurality of
layers. Consecutive layers are formed on top of one another to
construct a component having a desired shape.
A fuel injector 200 including the nozzle 204 improves the mixture
of air and fuel at the downstream end 226 of the nozzle body 220
and reduces emissions of a gas turbine engine 10. The reduction in
diameter of the upstream end 222 of the nozzle body 220 and
inclusion of the plurality of openings 238 therein, decrease the
amount of material in the nozzle body 220, and therefore its
weight. In addition, by forming the nozzle body 220 through an
additive manufacturing process, the number of components, and
therefore the complexity of the nozzle is reduced.
While the invention has been described in detail in connection with
only a limited number of embodiments, it should be readily
understood that the invention is not limited to such disclosed
embodiments. Rather, the invention can be modified to incorporate
any number of variations, alterations, substitutions or equivalent
arrangements not heretofore described, but which are commensurate
with the spirit and scope of the invention. Additionally, while
various embodiments of the invention have been described, it is to
be understood that aspects of the invention may include only some
of the described embodiments. Accordingly, the invention is not to
be seen as limited by the foregoing description, but is only
limited by the scope of the appended claims.
* * * * *